Electrical connector assembly with liquid cooling features

ABSTRACT

An electrical connector assembly includes a connector housing and a busbar having a rectangular cross section defining two opposed major surfaces and two opposed minor surfaces disposed within the connector housing. A planar surface is defined by one of the two opposed major surfaces of the busbar. The electrical connector assembly further includes a cooling plate that is sized, shaped, and arranged to be in conductive thermal contact with the planar surface of the busbar. The cooling plate is configured to reduce a temperature of the busbar.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part-application and claims thebenefit under 35 U.S.C. § 120 of co-pending U.S. patent application Ser.No. 16/801,245 filed on Feb. 26, 2020 which claimed the benefit under 35U.S.C. § 119(e) of U.S. Provisional Patent Application No. 62/827,425filed on Apr. 1, 2019 and U.S. Provisional Patent Application No.62/897,571 filed on Sep. 9, 2019, the entire disclosure of each of whichis hereby incorporated by reference.

TECHNICAL FIELD OF THE INVENTION

The invention relates to electrical connector assemblies, particularlyelectrical connector assemblies with liquid cooling features.

TECHNICAL FIELD OF THE INVENTION

The invention relates to electrical connectors, particularly electricalconnectors configured to accommodate a variety of different modularcooling features.

BACKGROUND OF THE INVENTION

High power electrical connector assemblies, such as those used with fastcharging systems for electrical vehicles must be designed to carry 90kilowatts of electrical power or more. Contact resistance betweenelectrical terminal elements in the electrical connector assembly maycause power losses which are converted to thermal energy within theconnector assembly. This thermal energy can cause a temperature risewithin the electrical connector assembly that may damage the assembly ifthermal limits are exceeded. Managing the terminal energy is alsoimportant in meeting industry performance standards, e.g. performancestandards published by Underwriters Laboratories (UL), Society ofAutomotive Engineers (SAE), and/or the International ElectrotechnicalCommission (IEC).

The subject matter discussed in the background section should not beassumed to be prior art merely because of its mention in the backgroundsection. Similarly, a problem mentioned in the background section orassociated with the subject matter of the background section should notbe assumed to have been previously recognized in the prior art. Thesubject matter in the background section merely represents differentapproaches, which in and of themselves may also be inventions.

BRIEF SUMMARY OF THE INVENTION

According to a first embodiment of the invention, an electricalconnector assembly is provided. The electrical connector assemblyincludes a connector housing and a busbar having a rectangular crosssection defining two opposed major surfaces and two opposed minorsurfaces disposed within the connector housing, wherein a planar surfaceis defined by one of the two opposed major surfaces of the busbar. Theelectrical connector assembly further includes a cooling plate sized,shaped, and arranged to be in conductive thermal contact with the planarsurface of the busbar and configured to reduce a temperature of thebusbar.

In an example embodiment having one or more features of the electricalconnector assembly of the previous paragraph, the cooling plate mayinclude a coolant channel in fluidic communication with an inlet portand an outlet port.

In an example embodiment having one or more features of the electricalconnector assembly any one of the previous paragraphs, the cooling platemay be configured to allow a liquid coolant to flow into the inlet port,through the coolant channel and out of the outlet port.

In an example embodiment having one or more features of the electricalconnector assembly any one of the previous paragraphs, the cooling platemay include a first portion defining the inlet port and the outlet portand a second portion having an outer surface in conductive thermalcontact with the planar surface of the busbar.

In an example embodiment having one or more features of the electricalconnector assembly any one of the previous paragraphs, the electricalconnector assembly may further include a primary seal disposedintermediate the first portion and the second portion.

In an example embodiment having one or more features of the electricalconnector assembly any one of the previous paragraphs, the electricalconnector assembly may further include a secondary seal that is disposedbetween the first portion and the connector housing.

In an example embodiment having one or more features of the electricalconnector assembly any one of the previous paragraphs, an inner surfaceof the first portion may define a plurality of cooling fins extendinginto the coolant channel.

In an example embodiment having one or more features of the electricalconnector assembly any one of the previous paragraphs, the busbar may bea first busbar and the planar surface may be a first planar surface. Theelectrical connector assembly may further include a second busbar havinga rectangular cross section defining two opposed major surfaces and twoopposed minor surfaces disposed within the connector housing. A secondplanar surface may be defined by one of the two opposed major surfacesof the second busbar. The cooling plate may be sized, shaped, andarranged to be in conductive thermal contact with the first planarsurface of the first busbar and in conductive thermal contact with thesecond planar surface of the second busbar and configured to reduce atemperature of the second busbar.

In an example embodiment having one or more features of the electricalconnector assembly any one of the previous paragraphs, the first andsecond planar surfaces may be adjacent curved surfaces of the first andsecond busbars.

In an example embodiment having one or more features of the electricalconnector assembly any one of the previous paragraphs, the electricalconnector assembly may further include a dielectric thermal interfacematerial layer intermediate the cooling plate and the first and secondplanar surfaces.

According to yet another embodiment of the invention, an electricalconnector assembly is provided. The electrical connector assemblyincludes a connector housing, a pair of busbars disposed within theconnector housing, and a means for reducing a temperature of the pair ofbusbars.

In an example embodiment having one or more features of the electricalconnector assembly of the previous paragraph, the electrical connectorassembly may further include a means for enclosing the pair of busbarswithin the connector housing.

In an example embodiment having one or more features of the electricalconnector assembly any one of the previous paragraphs, the electricalconnector assembly may further include a means for protecting thebusbars from environmental contaminants.

In an example embodiment having one or more features of the electricalconnector assembly any one of the previous paragraphs, the electricalconnector assembly may further include a means for electricallyisolating the pair of busbars from the means for reducing thetemperature of the pair of busbars.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

The present invention will now be described, by way of example withreference to the accompanying drawings, in which:

FIG. 1 is perspective front view of an electrical connector assemblyaccording to an embodiment of the invention;

FIG. 2 is an exploded perspective rear view of the electrical connectorassembly of FIG. 1 showing a plurality of different cover configurationsaccording to an embodiment of the invention;

FIG. 3 is a close-up perspective rear view of an opening in a connectorhousing of the electrical connector assembly of FIG. 1 according to anembodiment of the invention;

FIG. 4 is a perspective left side view of the electrical connectorassembly of FIG. 1 showing a cover having coolant tube running throughthe cover according to an embodiment of the invention;

FIG. 5 is a perspective right side view of the electrical connectorassembly of FIG. 4 according to an embodiment of the invention;

FIG. 6 is a perspective rear view of the electrical connector assemblyof FIG. 4 according to an embodiment of the invention;

FIG. 7 is a perspective bottom view of the cover of FIG. 6 according toan embodiment of the invention;

FIG. 8 is a schematic diagram of the coolant tube of the electricalconnector assembly of FIG. 4 interconnected with a cooling system of anelectrically propelled vehicle according to an embodiment of theinvention;

FIG. 9 is an exploded view of the electrical connector assembly of FIG.4 including a thermoelectric device according to an embodiment of theinvention;

FIG. 10 is an exploded view of the electrical connector assembly of FIG.1 showing a member having a coolant duct terminated by a pair of liquidports according to an embodiment of the invention;

FIG. 11 is a perspective left side view of the electrical connectorassembly of FIG. 10 showing a cover having the pair of liquid portsextending through an aperture in the cover according to an embodiment ofthe invention;

FIG. 12 is a perspective right side view of the electrical connectorassembly of FIG. 1 showing a cover having a pair of airflow portsextending through the cover according to an embodiment of the invention;

FIG. 13 is a partial exploded view of the electrical connector assemblyof FIG. 12 showing the cover and an interconnection between a pair ofterminals according to an embodiment of the invention;

FIG. 14 is a perspective bottom view of the cover of the electricalconnector assembly of FIG. 12 showing a baffle according to anembodiment of the invention;

FIG. 15 is a perspective rear view of the electrical connector assemblyof FIG. 1 showing a cover having a plurality of cooling fins extendingfrom the cover according to an embodiment of the invention;

FIG. 16 is a cross section view of the electrical connector assembly ofFIG. 15 according to an embodiment of the invention;

FIG. 17 is an exploded perspective view of an electrical connectorassembly according to an embodiment of the invention;

FIG. 18 is an isolated view of a liquid cooling plate of the electricalconnector assembly of FIG. 17 according to an embodiment of theinvention;

FIG. 19 is an exploded view of the liquid cooling plate of FIG. 18according to an embodiment of the invention;

FIG. 20 is a cross section view of the electrical connector assembly ofFIG. 17 according to an embodiment of the invention;

FIG. 21 is a graph of the temperature of various components electricalconnector assembly of FIG. 17 while conducting 500 amperes according toan embodiment of the invention;

FIG. 22 is a graph of the temperature of various components electricalconnector assembly of FIG. 17 while conducting 600 amperes according toan embodiment of the invention;

FIG. 23 is a graph of the temperature of various components electricalconnector assembly of FIG. 17 compared to an alternative cooling systemaccording to an embodiment of the invention;

FIG. 24A is a temperature gradient top view of the liquid cooling plateof FIG. 18 according to an embodiment of the invention;

FIG. 24B is a temperature gradient bottom view of the liquid coolingplate of FIG. 18 according to an embodiment of the invention;

FIG. 25A is a perspective view of an electrical connector assembly in apartially assembled condition according to another embodiment of theinvention;

FIG. 25B is a front view of a printed circuit board subassembly of theelectrical connector assembly of FIG. 25A according to an embodiment ofthe invention.

FIG. 25C is a close-up view of the printed circuit board subassembly ofFIG. 25B according to an embodiment of the invention;

FIG. 25D is a cross-section view of the printed circuit boardsubassembly of FIG. 25B according to an embodiment of the invention;

FIG. 26 is an isolated perspective view of the liquid cooling plate ofFIG. 18 and a pair of busbars of FIG. 20 according to an embodiment ofthe invention;

FIG. 27 is an isolated top view of the liquid cooling plate and the pairof busbars according to an embodiment of the invention; and

FIG. 28 is an isolated bottom view of the liquid cooling plate and thepair of busbars according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to embodiments, examples of whichare illustrated in the accompanying drawings. In the following detaileddescription, numerous specific details are set forth to provide athorough understanding of the various described embodiments. However, itwill be apparent to one of ordinary skill in the art that the variousdescribed embodiments may be practiced without these specific details.In other instances, well-known methods, procedures, components,circuits, and networks have not been described in detail so as not tounnecessarily obscure aspects of the embodiments.

FIGS. 1 through 16 illustrate a non-limiting example of an electricalconnecter assembly embodying features of the invention. The illustratedexample of the electrical connector assembly, hereinafter referred to asthe assembly 10, serves a charging port of an electrically propelledvehicle. As used herein, the term “electrically propelled vehicle” mayrefer to an electric vehicle which is propelled solely by an electricmotor or a hybrid electric vehicle which is propelled by an electricmotor in some combination with a combustion engine. The assembly 10 asillustrated conforms to Society of Automotive Engineers (SAE)Specification J1772 Combined Charging System. The assembly 10 has acombination of electrical terminals 12 for lower power alternatingcurrent (AC) charging of the vehicle battery and a pair of DC terminals14 for higher power direct current (DC) charging of the vehicle battery,as shown in FIG. 1. Other charging port standards, such as standardspublished by the CHAdeMO Association, use a similar pair of DCterminals.

As shown in FIG. 2, the assembly includes a connector housing,hereinafter referred to as the housing 16, that defines a cavity 18 inwhich the DC terminals 14 are disposed. As can be seen by referencingFIGS. 3, 8, and 16, the DC terminals 14 are interconnected to cableterminals 20 of insulated wire cables connecting the assembly 10 to thebattery pack 22 of the vehicle. The DC terminals 14 carry power levelsof 90 kilowatts or more which can cause the temperature to rise withinthe cavity 18 during the battery charging operation. The assembly 10further includes a cover that is configured to enclose the cavity 18,thereby protecting the DC terminals 14 and the cable terminals 20. Thecover is also configured to thermally manage heat within the cavity 18by removing thermal energy from the cavity 18.

The housing 16 is designed to receive and accommodate several differentcover configurations 100, 200, 300, 400, 500. Each of the coverconfigurations 100, 200, 300, 400, 500 uses a different thermalmanagement mechanism to thermally manage heat within the cavity 18. Thecover configurations 100, 200, 300, 400, 500 include active thermalmanagement mechanisms such as one or more liquid ports that areconfigured to receive a liquid coolant flow within the cavity 18, one ormore thermoelectric cooling plates, and/or one or more airflow portsthat are configured to receive an airflow within the cavity 18 and/orpassive thermal management mechanisms, such as one or more cooling fins502 projecting from the cover 500.

In a first cover configuration 100 having an active thermal managementmechanism shown in FIGS. 4-8, the cover 100 comprises an active thermalmanagement system featuring an enclosed coolant tube 102 that isconfigured to carry a liquid coolant flow through the cover 100. Thecoolant tube has a liquid inlet port 104 and a liquid outlet port 106that is interconnected with the vehicle's cooling system 24, e.g. aliquid cooling system that cools the vehicle battery pack 22 and/or thevehicle power electronics as illustrated in FIG. 8. The vehicle'scooling system 24 includes a pump or other fluid movement device thatcauses the liquid coolant to flow through the cooling tube. As shown inFIGS. 4, 6, and 7, the coolant tube follows a serpentine path throughthe cover, thereby increasing the length of the coolant tube andincreasing the amount of thermal energy that can be absorbed from thecavity 18 by the coolant it flows through the cover. The cover maypreferably be formed on a material with a high thermal conductivity,such as an aluminum or copper-based material, to provide adequatethermal transfer between the cavity 18 and the liquid coolant.Alternatively, the cover may be formed of a thermally conductivepolymer.

According to a second cover configuration 200 an active thermalmanagement mechanism shown in FIG. 9, the cover 200 includes athermoelectric device 202 which uses the Peltier effect to actively coolthe cavity 18. An electrical voltage is applied to the thermoelectricdevice 202 such that a side 204 of the thermoelectric device 202 facinginwardly toward the cavity 18 is cooled while another side 206 of thethermoelectric device 202 facing outward is heated by the thermal energyremoved from the cooled side 204. The thermoelectric device 202 may beused as the sole thermal management mechanism in the assembly 10 orcombined with any one of the other described cover configurations 100,300, 400, 500.

In a third cover configuration 300 an active thermal managementmechanism illustrated in FIGS. 10 and 11, the assembly 10 furthercomprises an electrically nonconductive terminal position assurance(TPA) member 302 that encloses a portion of the DC terminals 14 and isin thermal communication with the DC terminals 14. The TPA member 302comprises a coolant duct configured to carry a liquid coolant flowthrough the TPA member 302. The TPA member 302 provide s the benefit ofremoving thermal energy directly from the DC terminals 14 which are oneof the primary heat sources within the cavity 18. The coolant duct has aliquid inlet port 304 and a liquid outlet port 306 that isinterconnected with the vehicle's cooling system 24, e.g. a liquidcooling system that cools the vehicle battery pack 22 and/or the vehiclepower electronics similar to the illustration of FIG. 8. The vehicle'scooling system 24 includes a pump that causes the liquid coolant to flowthrough the cooling duct. The cover 300 defines an aperture 308 throughwhich the liquid inlet port 304 and the liquid outlet port 306 exit thecavity 18. In an alternative embodiment, the liquid inlet port 304 andthe liquid outlet port 306 may be interconnected with a cooling systemdedicated to cooling the assembly 10.

A fourth cover configuration 400 having an active thermal managementmechanism is illustrated in FIGS. 12-14. The cover 400 is in pneumaticand thermal communication with the cavity 18. The cover 400 includes anairflow inlet port 402 though which airflow of air at the vehicle'sambient temperature enters the cavity 18 and an airflow outlet port 404through which the airflow is exhausted from the cavity 18. The airflowinlet port 402 is interconnected to an airflow generating device of thevehicle, such as a ducted fan. The airflow through the cavity 18 removessome of the thermal energy from the cavity 18, thereby lowing thetemperature within the cavity 18. An inner surface of the cover 400defines a baffle 406 configured to direct the airflow within the cavity18. The baffle 406 also includes a curved surface 408 that helps tocreate a turbulent airflow within the cavity 18. The cover 400 and thebaffle 406 may be preferably formed of a dielectric polymer material toavoid short circuiting that may be caused by contact between the baffle406 and any of the terminals within the cavity 18.

A fifth cover configuration 500 having passive thermal managementmechanism is illustrated in FIGS. 15 and 16. The cover 500 is formed ofa thermally conductive material such an aluminum or copper basedmaterial and has a number of parallel cooling fins 502 protruding fromthe cover 500. Alternatively, the cover 500 may be formed of a thermallyconductive polymer. In this configuration the cavity 18 is filled with adielectric thermally conductive potting material 504, such as an epoxyor silicone-based material that is in thermal communication with thecover 500. A silicone thermal grease may be applied intermediate thepotting material 504 and the interior surface 506 of the cover 500.

In an alternative embodiment, the cavity 18 may be filled with adielectric phase changing material (PCM). A PCM is a substance with ahigh heat of fusion, e.g. paraffins or lipids. The PCM melts andsolidifies at a near constant temperature and can store and releasinglarge amounts of thermal energy. Heat is absorbed within the cavity 18as the PCM gradually changes from a solid state to a liquid state whenpower is flowing through the terminals 14, 20 and then heat is graduallyreleased through the cover 500 as the PCM changes from the liquid stateback to the solid state when power is no longer flowing through theterminals 14, 20.

The potting material 504 and the phase change material used must have abreakdown voltage that is higher than the charging voltage of thevehicle charging system to which the assembly 10 is connected.

Alternative embodiments of the assembly 10 may be envisioned combiningvarious elements described above. For example, the thermal pottingmaterial 504 or PCM of the fifth cover configuration 500 may beincorporated into the first, second or third cover configurations 100,200, 300. In alternative embodiments, the cooling fins 502 of the fifthcover configuration 500 could be integrated into the first, second,third, or fourth cover configuration 100, 200, 300, 400.

In a sixth cover configuration 600, an active thermal managementmechanism illustrated in FIGS. 17 through 24B, the cover 600 is inintimate thermal and physical contact with busbars that are a part ofthe DC terminals 14 within the cavity 18. As shown in FIG. 18, the cover600 includes a top cover 626 having a liquid inlet port 604 and a liquidoutlet port 606 that is interconnected with the vehicle's cooling system24, e.g. a liquid cooling system that cools the vehicle battery pack 22and/or the vehicle power electronics similar to the illustration of FIG.8. The vehicle's cooling system 24 includes a pump that causes theliquid coolant to flow through the cooling duct. In an alternativeembodiment, the liquid inlet port 604 and the liquid outlet port 606 maybe interconnected with a cooling system dedicated to cooling theassembly 10. The top cover 626 may be advantageously formed of apolymeric material to reduce weight of the top cover 626 and providebetter electrical isolation compared to a metal top cover 626.

As shown in FIG. 19, the cover 600 also includes a bottom cover 628 thatdefines a coolant duct having a plurality of cooling fins 630 thatdefine a plurality of coolant channels 632, best illustrated in FIG. 20,through which a liquid coolant flows from the liquid inlet port 604 tothe liquid outlet port 606. The bottom cover 628 may be advantageouslyformed of a metallic material to optimize heat transfer between thecooling fins 630 and the liquid coolant. As illustrated in FIG. 20, itis the bottom cover 628 that is in intimate thermal contact with thebusbar portion of the DC terminals 14. The bottom cover 628 furtherincludes a dielectric thermal interface material layer 634, such asTHERM-A-GAP™ GEL 30 distributed by Parker Chomerics of Woburn, Mass.,that is in direct contact with the DC terminals 14 and an additionaldielectric material layer 636, such as ISOEDGE PR4305 distributed byHenkel Corporation of Warren, Mich., that is disposed intermediate thedielectric thermal interface material layer 634 and the coolant channels632. The dielectric thermal interface material layer 634 and theadditional dielectric material layer 636 provide robust electricalisolation between the busbar portion of the DC terminals 14 and themetallic bottom cover 628.

The cover 600 also includes a primary coolant seal 638 between the topcover 626 and the bottom cover 628 and a secondary seal 640 between thecover 600 and the cavity 18 to ensure that the liquid coolant does notenter the cavity 18. The primary and secondary seals 638, 640 areadvantageously formed of a compliant material, such as a silicone-basedrubber material. The primary and secondary seals 638, 640 inhibitingress of the liquid coolant into the cavity 18 that could cause ashort circuit between the DC terminals 14.

Experimental results of the cooling performance of the cover 600 areshown in FIGS. 21-24B. FIG. 21 shows the temperature 642 of one of theelectrical terminals 12, the temperature 644 of one of the terminals 14,and the inlet coolant temperature 646 as the assembly 10 is operatedwith a current of 500 amperes. FIG. 22 shows the temperature 648 of oneof the electrical terminals 12, the temperature 650 of one of theterminals 14, and the inlet coolant temperature 652 as the assembly 10is operated with a current of 500 amperes. FIG. 23 shows a comparison ofthe temperature 654 of one of the electrical terminals 12 and thetemperature 656 of one of the terminals 14 with a cover having passivecooling, such as cover 100 with the temperature 658 of one of theelectrical terminals 12, the temperature 660 of one of the terminals 14,and the inlet coolant temperature 662 as the assembly 10 under similaroperating conditions. FIG. 24A shows the thermal gradient between theliquid inlet port 604 and the liquid outlet port 606 of the top cover626 when the dissipated power is 100 watts. FIG. 24B shows the thermalgradient between the terminals 14 and the top cover 626 when thedissipated power is 100 watts.

As shown in FIG. 26, the busbars 14 each have a rectangular crosssection defining two opposed major surfaces and two opposed minorsurfaces. Planar surfaces 664 are defined by the two upper majorsurfaces of the busbars 14. The cover 600 forms a cooling plate 600 thatis sized, shaped, and arranged to be in conductive thermal contact withthe planar surfaces 664 of the busbars 14. The cooling plate 600 isconfigured to reduce the temperature of the busbars 14 when the assembly10 is conducting electrical power. The second cover portion 628 has aplanar outer surface 668 that is in conductive thermal contact with andis coplanar to the planar surfaces of the busbars 14. As used herein“conductive thermal contact” means that conduction is the primary modeof heat transfer between the busbars 14 and the cooling plate 600, i.e.the percentage of heat transfer by conduction is greater than thepercentage of heat transfer by radiation or convection and may begreater than the percentage of heat transfer by radiation andconvection. In the non-limiting example illustrated in FIGS. 26-28, theplanar outer surface 668 of the cooling plate 600 is in intimatephysical contact with the dielectric thermal interface material layer634 which is in intimate physical contact with the planar surfaces 664of the busbars 14.

As shown in FIGS. 27 and 28, the cooling plate 600 is shaped, sized, andarranged such that the cooling plate 600 is in conductive thermalcontact with the entirely of the planar surfaces 664 of the busbars 14in order to maximize heat transfer between the busbars 14 and thecooling plate 600. The planar surfaces 664 of the busbars 14 areadjacent curved surfaces of the busbars 14 as shown in FIG. 26.

While the illustrated embodiment of cover 600 is configured to conduct aliquid coolant, other embodiments of the cover 600 may be envisionedthat are configured to conduct a gaseous coolant.

Alternative embodiments may be envisioned which include features ofseveral of the embodiments described above. Table 1 below describes atleast some of the possible combinations.

TABLE 1 Cover Configurations Cavity Cover Additional Type ContentsConfiguration Components Passive 1 Still Air Polymer None Passive 2Thermal Potting Thermally Conduc- None Material tive Polymer Passive 3Thermal Potting Externally None Material Finned Metal Passive 4 PhaseChange Thermally Conduc- None Material tive Polymer Passive 5 PhaseChange Externally None Material Finned Metal Passive 6 Still AirThermally Conduc- Thermal Interface tive Polymer Material Passive 7Still Air Externally Thermal Interface Finned Metal Material Active 1Moving Air Polymer with None Ports and Baffles Active 2 Thermal PottingCooling Plate None Material Active 3 Thermal Potting Cooling PlateThermoelectric Material Device Active 4 Still Air Pass Trough CooledPolymer Terminal Position Assurance Device Active 5 Still Air PassTrough Cooled Metallic Isolated Terminal Position Assurance DeviceActive 6 Still Air Cooling Plate Thermal Interface Material Active 7Still Air Cooling Plate Thermal Interface with Internal Material Layer,Fins Insulation Layer, Primary and Secondary Seals

FIGS. 25A-25D illustrate an electrical connector assembly that includestemperature sensing capability for terminals within the assembly. Anelectrical temperature sensor is near the electrical terminals toimprove thermal sensing response time for the terminals. Thermalcontacts are used to bridge the distance between the terminal and thetemperature sensors, thereby further improving improve thermal sensingresponse time for the terminals.

As illustrated in the non-limiting examples of FIGS. 25B-25D, theelectrical connector assembly 10 includes a printed circuit board 712that has an electrical temperature sensor 714, such as a surface mountedthermistor mounted on the printed circuit board 712. The electricalconnector assembly 10 also includes at least one terminal 716 that isdisposed within an aperture 718 extending through the printed circuitboard 712. The electrical connector assembly 10 further includes athermally conductive contact spring 720 that is attached to the printedcircuit board 712 in a location proximate to the electrical temperaturesensor 714. As best shown in FIG. 25C, the electrical connector assembly10 may additionally include a thermally conductive material 722 thatcovers a portion of the spring 720 where it is attached to the printedcircuit board 712 and extends to also cover the electrical temperaturesensor 714. The contact spring 720 may also be used to transmitelectrical signals between the printed circuit board 712 and theterminal 716.

The printed circuit board 712 may have several electrical temperaturesensors 716 mounted thereon as shown in FIG. 25B and the electricaltemperature sensors 716 may share a common ground circuit.

While the illustrated example of the electrical connecter assembly 10 isa vehicle charging port, other embodiments of this invention may beenvisioned for many other types of electrical connector assemblies.

Accordingly, an electrical connector assembly 10 is provided. Theassembly 10 provides the benefits of reducing the temperature of thebusbars 14 in the assembly 10. The cooling plate is shaped, sized, andarranged to provide maximum cooling of the busbars 14 when the assembly10 is conducting electrical power.

While this invention has been described in terms of the preferredembodiments thereof, it is not intended to be so limited, but ratheronly to the extent set forth in the claims that follow. For example, theabove-described embodiments (and/or aspects thereof) may be used incombination with each other. In addition, many modifications may be madeto configure a situation or material to the teachings of the inventionwithout departing from its scope. Dimensions, types of materials,orientations of the various components, and the number and positions ofthe various components described herein are intended to defineparameters of certain embodiments and are by no means limiting and aremerely prototypical embodiments.

Many other embodiments and modifications within the spirit and scope ofthe claims will be apparent to those of skill in the art upon reviewingthe above description. The scope of the invention should, therefore, bedetermined with reference to the following claims, along with the fullscope of equivalents to which such claims are entitled.

As used herein, ‘one or more’ includes a function being performed by oneelement, a function being performed by more than one element, e.g., in adistributed fashion, several functions being performed by one element,several functions being performed by several elements, or anycombination of the above.

It will also be understood that, although the terms first, second, etc.are, in some instances, used herein to describe various elements, theseelements should not be limited by these terms. These terms are only usedto distinguish one element from another. For example, a first contactcould be termed a second contact, and, similarly, a second contact couldbe termed a first contact, without departing from the scope of thevarious described embodiments. The first contact and the second contactare both contacts, but they are not the same contact.

The terminology used in the description of the various describedembodiments herein is for the purpose of describing embodiments only andis not intended to be limiting. As used in the description of thevarious described embodiments and the appended claims, the singularforms “a”, “an” and “the” are intended to include the plural forms aswell, unless the context clearly indicates otherwise. It will also beunderstood that the term “and/or” as used herein refers to andencompasses all possible combinations of one or more of the associatedlisted items. It will be further understood that the terms “includes,”“including,” “comprises,” and/or “comprising,” when used in thisspecification, specify the presence of stated features, integers, steps,operations, elements, and/or components, but do not preclude thepresence or addition of one or more other features, integers, steps,operations, elements, components, and/or groups thereof.

As used herein, the term “if” is, optionally, construed to mean “when”or “upon” or “in response to determining” or “in response to detecting,”depending on the context. Similarly, the phrase “if it is determined” or“if [a stated condition or event] is detected” is, optionally, construedto mean “upon determining” or “in response to determining” or “upondetecting [the stated condition or event]” or “in response to detecting[the stated condition or event],” depending on the context.

Additionally, while terms of ordinance or orientation may be used hereinthese elements should not be limited by these terms. All terms ofordinance or orientation, unless stated otherwise, are used for purposesdistinguishing one element from another, and do not denote any order ofoperations, direction or orientation unless stated otherwise.

The invention claimed is:
 1. An electrical connector assembly,comprising: a connector housing; a busbar having a planar surface; acooling plate sized, shaped, and arranged to be in conductive thermalcontact with the planar surface of the busbar and configured to reduce atemperature of the busbar, wherein the cooling plate comprises: a firstportion defining an inlet port and an outlet port, a coolant channel influidic communication with the inlet port and the outlet port, and asecond portion having an outer surface in conductive thermal contactwith the planar surface of the busbar; a primary seal disposedintermediate the first portion and the second portion; and a secondaryseal disposed between the first portion and the connector housing. 2.The electrical connector assembly of claim 1, wherein the cooling plateis configured to allow a liquid coolant to flow into the inlet port,through the coolant channel and out of the outlet port.
 3. Theelectrical connector assembly of claim 1, wherein the busbar is a firstbusbar and the planar surface is a first planar surface and wherein theelectrical connector assembly further comprises: a second busbar havinga rectangular cross section defining two opposed major surfaces and twoopposed minor surfaces disposed within the connector housing, wherein asecond planar surface is defined by one of the two opposed majorsurfaces of the second busbar, wherein the cooling plate is sized,shaped, and arranged to be in conductive thermal contact with the firstplanar surface of the first busbar and in conductive thermal contactwith the second planar surface of the second busbar and configured toreduce a temperature of the second busbar.
 4. The electrical connectorassembly of claim 3, wherein the first and second planar surfaces areadjacent to curved surfaces of the first and second busbars.
 5. Theelectrical connector assembly of claim 3, further comprising: adielectric thermal interface material layer intermediate the coolingplate and the first and second planar surfaces.
 6. An electricalconnector assembly, comprising: a connector housing; a busbar having aplanar surface; and a cooling plate sized, shaped, and arranged to be inconductive thermal contact with the planar surface of the busbar andconfigured to reduce a temperature of the busbar, wherein the coolingplate comprises: a first portion defining an inlet port and an outletport, a coolant channel in fluidic communication with the inlet port andthe outlet port, wherein the first portion defines a plurality ofcooling fins extending into the coolant channel, and a second portionhaving an outer surface in conductive thermal contact with the planarsurface of the busbar.
 7. The electrical connector assembly of claim 6,wherein the cooling plate is configured to allow a liquid coolant toflow into the inlet port, through the coolant channel and out of theoutlet port.
 8. The electrical connector assembly of claim 6, furthercomprising a primary seal disposed intermediate the first portion andthe second portion.
 9. The electrical connector assembly of claim 6,further comprising: a means for protecting the busbars fromenvironmental contaminants.
 10. The electrical connector assembly ofclaim 6, further comprising: a means for electrically isolating the pairof busbars from the means for reducing the temperature of the pair ofbusbars.
 11. The electrical connector assembly of claim 6, wherein thebusbar is a first busbar and the planar surface is a first planarsurface and wherein the electrical connector assembly further comprises:a second busbar having a rectangular cross section defining two opposedmajor surfaces and two opposed minor surfaces disposed within theconnector housing, wherein a second planar surface is defined by one ofthe two opposed major surfaces of the second busbar, wherein the coolingplate is sized, shaped, and arranged to be in conductive thermal contactwith the first planar surface of the first busbar and in conductivethermal contact with the second planar surface of the second busbar andconfigured to reduce a temperature of the second busbar.
 12. Theelectrical connector assembly of claim 11, wherein the first and secondplanar surfaces are adjacent to curved surfaces of the first and secondbusbars.
 13. The electrical connector assembly of claim 11, furthercomprising: a dielectric thermal interface material layer intermediatethe cooling plate and the first and second planar surfaces.